Side-by-side atv

ABSTRACT

The present invention relates to all terrain vehicles having at least a pair of laterally spaced apart seating surfaces. More particularly, the present invention relates to trail compliant side-by-side all terrain vehicles.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority from U.S. patent applicationSer. No. 14/478,700 filed on Sep. 5, 2014, which in turn claimedpriority from U.S. patent application Ser. No. 11/494,890 filed on Jul.28, 2006, now U.S. Pat. No. 8,827,028 issued Sep. 9, 2014, the subjectmatter of which are all incorporated herein by reference. The presentapplication is related to U.S. patent application Ser. No. 13/776,588filed Feb. 25, 2013 which is a division of Ser. No. 12/409,176 filedMar. 23, 2009, now U.S. Pat. No. 8,382,125 issued Feb. 26, 2009; whichis a continuation of Ser. No. 11/494,891 filed on Jul. 28, 2006, nowU.S. Pat. No. 7,819,220 issued Oct. 26, 2010; the subject matter ofwhich are all incorporated herein by reference. The present applicationis also related to U.S. patent application Ser. No. 14/094,747 filedDec. 2, 2014 which is a continuation of Ser. No. 12/925,560 filed Oct.25, 2010, now U.S. Pat. No. 8,596,405 issued Dec. 3, 2013, which is acontinuation of Ser. No. 11/494,891 filed on Jul. 28, 2006, now U.S.Pat. No. 7,819,220 issued Oct. 26, 2010; the subject matter of which areall incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to side-by-side all terrain vehicleshaving at least a pair of laterally spaced apart seating surfaces. Moreparticularly, the present invention relates to trail compliantside-by-side all terrain vehicles.

BACKGROUND OF THE INVENTION

Generally, all terrain vehicles (“ATVs”) and utility vehicles (“UVs”)are used to carry one or two passengers and a small amount of cargo overa variety of terrains. Due to increasing recreational interest in ATVs,specialty ATVs, such as those used for trail riding, racing, and cargohauling have entered the market place. Most ATVs include seating for upto two passengers which are either seated side-by-side or with thepassenger positioned behind the driver of the ATV. Side-by-side ATVs, inwhich the driver and passenger are seated beside each other on laterallyspaced apart seats, have become popular because of the ability to allowthe passenger to share the driver's viewpoint and riding experienceinstead of being positioned behind the driver. Due to the side-by-sideseating arrangement, most side-by-side ATVs have a width of at least 54inches (137 centimeters). Increasing numbers of ATV riders are enjoyingrecreational trail riding through public lands including state parks andnational forests. Most trails on such public lands have a mandatedmaximum width requirement to limit damage to the environment. Forexample, most parks have established a maximum trail width of about 50inches, making the use of most side-by-side ATVs on trails unacceptableor impractical.

SUMMARY OF THE INVENTION

According to one illustrative embodiment of the present disclosure, anall-terrain vehicle comprises a frame; a front suspension comprising atleast one right front control arm and one left front control arm, thefront control arms being coupled to the frame, and a front torsion barcoupled between the front control arms; at least two front wheelscoupled to the front suspension; a rear suspension comprising at leastone right rear control arm and one left rear control arm, the rearcontrol arms being coupled to the frame, and a rear torsion bar coupledbetween the rear control arms; at least two rear wheels coupled to therear suspension; a seating area supported by the frame and comprisingside by side seats each having a seat back and a seat bottom; a fueltank being positioned underneath one of the seat bottoms; a rear axleassembly drivingly coupling the transmission to the rear wheels; amodular engine assembly supported by the frame, the modular engineassembly being comprised of an engine, a transmission comprising acontinuously variable transmission and at least a portion of the rearaxle assembly, the portion of the rear axle assembly having a rear driveaxis, wherein the modular engine assembly is capable of being mounted toor dismounted from the frame as a unit. The continuously variabletransmission comprises a clutch mechanism adapted to transmit power fromthe engine to the transmission; a clutch housing covering the clutchmechanism, and a clutch cooling intake which communicates with theclutch housing to cool the clutch mechanism. The modular engine assemblybeing positioned rearward of the seating area and being mounted to theframe by first and second mounting assemblies, where the first mountingassembly is coupled to the rear axle assembly rearward of the rear driveaxis and wherein the second mounting assembly is coupled to the engine.A front axle assembly is supported by the frame and drivingly couplingthe transmission to the front wheels; a front end comprising an outerfront panel having outer fenders and a hood; a cab including a steeringwheel and a transmission shift lever, the seating area being positionedwithin the cab; a rear end including an engine cover; a protective cagepositioned over the cab including front and rear frame tubes extendingupwardly from the cab to form the protective cage; and wherein outermostpoints of the vehicle in a width-wise direction define a width of lessthan 54 inches.

The above mentioned and other features of this invention, and the mannerof attaining them, will become more apparent and the invention itselfwill be better understood by reference to the following description ofembodiments of the invention taken in conjunction with the accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of one embodiment of a side-by-side ATV;

FIG. 2 is a profile view of the side-by-side ATV shown in FIG. 1;

FIG. 3 is a front view of the ATV shown in FIGS. 1 and 2;

FIG. 4 is a top plan view of the side-by-side ATV shown in FIGS. 1through 3;

FIG. 5 is a partial perspective view of the cab area of the side-by-sideATV shown in FIGS. 1 through 4;

FIG. 6 is a partial profile view of the cab area shown in FIG. 5;

FIG. 7 is a partial perspective view of one embodiment of a guard railthat may be used on a side-by-side ATV, such as the side-by-side ATVshown in FIG. 1;

FIG. 8 is another embodiment of a guard rail that may be used on aside-by-side ATV, such as the side-by-side ATV shown in FIG. 1;

FIG. 9 is a bottom plan view of the side-by-side ATV shown in FIGS. 1through 4;

FIG. 10 is a partially exploded, perspective view of the front end ofthe ATV shown in FIGS. 1 through 4;

FIG. 11 is a partially exploded, perspective view similar to FIG. 10showing hood mounting details;

FIG. 12 is a cross-sectional view illustrating the hood mounting withthe hood partially removed from the front panel;

FIG. 13 is a cross-sectional view similar to FIG. 12 with the hoodcoupled to the front panel;

FIG. 14 is a rear perspective view of the frame and the modular engineassembly of the side-by-side ATV shown in FIGS. 1 through 4;

FIG. 15 is a partially exploded, rear perspective view of the frame andmodular engine assemblies shown in FIG. 14;

FIG. 16 is an exploded perspective view of one embodiment of an enginemounting assembly that may be used on an ATV such as the side-by-sideATV shown in FIGS. 1 through 4;

FIG. 17 is an exploded perspective view of another embodiment of anengine mounting assembly that may be used on an ATV such as theside-by-side ATV shown in FIGS. 1 through 4;

FIG. 18 is an exploded perspective view of yet another embodiment of anengine mounting assembly that may be used on an ATV such as theside-by-side ATV shown in FIGS. 1 through 4;

FIG. 19 is a partial front perspective view of the bottom side of thedrive train components of the side-by-side ATV shown in FIGS. 1 through4;

FIG. 20 is a partially exploded rear view of components of the frame andrear suspension system of the side-by-side ATV shown in FIGS. 1 through4;

FIG. 21 is a rear view of the frame and suspension system of the ATVshown in FIG. 20;

FIG. 22 is a partial rear perspective view of a steering mechanism andfront axle assembly that may be used on an ATV such as the side-by-sideATV shown in FIGS. 1 through 4;

FIG. 23 is a partial front perspective view of the steering mechanismand front axle assembly of the ATV shown in FIG. 22;

FIG. 24 is a partial perspective view of one embodiment of a brakingassembly that may be used on an ATV such as the side-by-side ATV shownin FIGS. 1 through 4;

FIG. 25 is an elevated rear perspective view of the engine and clutchcooling components of the side-by-side ATV shown in FIGS. 1 through 4;

FIG. 26 is a partial rear view of the engine and clutch coolingcomponents shown in FIG. 25;

FIG. 27 is a partial perspective view of the driver's side foot wellarea of the ATV shown in FIGS. 1 through 4;

FIG. 28 is an partial exploded view of a steering assembly that may beused on an ATV such as the side-by-side ATV shown in FIGS. 1 through 4;

FIG. 29 is a side elevational view of the steering assembly of FIG. 28,showing the steering wheel in various tilted positions; and

FIG. 30 is a partial perspective view of an adjustable grab bar that maybe used on an ATV such as the side-by-side ATV shown in FIGS. 1 through4.

Corresponding reference characters indicate corresponding partsthroughout the several views. Although the drawings representembodiments of the present invention, the drawings are not necessarilyto scale and certain features may be exaggerated in order to betterillustrate and explain the present invention.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

The embodiments disclosed below are not intended to be exhaustive or tolimit the invention to the precise forms disclosed in the followingdetailed description. Rather, the embodiments are chosen and describedso that others skilled in the art may utilize their teachings. Forexample, while the following description refers primarily to a ATV,certain features described herein may be applied to other applicationssuch as UVs, snowmobiles, motorcycles, mopeds, etc.

Referring initially to FIG. 1, one illustrative embodiment ofside-by-side ATV 10 is shown. ATV 10 includes front end 12 and rear end14, and a frame 15 which is supported above the ground surface by a pairof front tires 22 a and wheels 24 a and a pair of rear tires 22 b andwheels 24 b. ATV 10 includes a pair of laterally spaced-apart upper andlower seating surfaces 18 a, 18 b and 20 a, 20 b, respectively. Theupper seating surfaces 18 a, 18 b are configured to support the backs ofsitting riders, while the lower seating surfaces 20 a, 20 b areconfigured to support the buttocks of sitting riders. In theillustrative embodiment, upper and lower seating surfaces 18 a, 18 b,and 20 a, 20 b form a bucket seat arrangement, however a bench styleseat or any other style of seating structure may be used. Upper andlower seating surfaces 18 and 20 are positioned within cab 17 of ATV 10.

Protective cage 16 extends over cab 17 to assist in preventing injury topassengers of ATV 10 from passing branches or tree limbs, as well as,may act as a support in the event of a vehicle rollover. As shown inFIGS. 1 through 4, protective cage 17 narrows as it extends upwardly toallow the driver and passenger easier entry and exit of cab 17.Additionally, in some embodiments a cover including one or more of aroof, windshield and doors (not shown) may be attached to the protectivecage 16 to block weathering elements such as wind, rain or snow. Cab 17also includes front console 31, adjustable steering wheel 28, and shiftlever 29. Front console 31 may include a tachometer, speedometer, or anyother suitable instrument. Front end 12 of ATV 10 includes front panel67, hood 32, and front suspension assembly 26. Front suspension assembly26 pivotally couples front wheels 24 to ATV 10. Rear end 14 of ATV 10includes engine cover 19 which extends over modular engine assembly 34,as shown in FIGS. 2, 14, and 15. Modular engine assembly 34 isillustratively positioned completely behind upper and lower seatingsurfaces 18 a, 18 b, and 20 a, 20 b.

As shown in FIG. 2, front wheels 24 are supported for rotation by frontaxle 36. Similarly, rear wheels 24 b are supported for rotation by rearaxle 38. In the illustrative embodiment shown in FIG. 2, wheelbase A,which extends between the center of front axle 36 and the center of rearaxle 38, is equal to about 77 inches (195.6 centimeters). Seat height Bis equal to the distance between a low point 21 of lower seatingsurfaces 20 and a bottom of the frame 15 when ATV 10 is at rest. In theillustrative embodiment, seat height B is equal to about 11.75 inches(29.8 centimeters). In the illustrative embodiment, the ratio of thewheelbase to the seat height, or distance A to distance B, is about 6.55to 1. In other embodiments, not shown, the ratio of the wheelbase to theseat height may be equal to other suitable ratios, however the presentinvention contemplates ATVs having a ratio of wheelbase to seat heightgreater than about 6.0 to 1. A wheelbase to seat height ratio greaterthan about 6.0 to 1 facilitates a relatively low vehicle center ofgravity and further provides improved ergonomics, handling, and spaceutilization.

Referring now to FIGS. 3 and 4, a front view and top plan view of ATV 10is shown. In the illustrative embodiment, width C, which is defined asthe overall width of ATV 10, extends between the outermost lateralpoints of ATV 10. In the illustrative embodiment, outer surfaces oftires 22 on the front and rear ends of ATV 10 define the outermostpoints. In other embodiments, width C may be measured from the outerfenders of front panel 67. It may be appreciated that width C may bedefined by both the outer surfaces of tires 22 and fenders of frontpanel 67, should the respective dimensions be substantially equal. Inthe illustrative embodiment, width C is about 50 inches. In otherembodiments, ATV 10 may be constructed to other suitable widths, howeverthe present invention contemplates ATVs having a trail compliant widthor less than about 54 inches.

Referring now to FIG. 5, a partial view of cab 17 of ATV 10 is shown.Lower seating surfaces 20 are coupled to base 41 of ATV 10. Foot wellarea 40 extends below base 41 and encloses each passenger's feet andlower leg portions. Foot well area 40 includes floorboard 42 and sidepanel 46 on each side of ATV 10. Floorboard 42 includes an aperture 44positioned to allow fluid to drain out of floorboard 42. Side panel 46extends upwardly from floorboards 42 on each side of ATV 10. In theillustrative embodiment, side panels 46 extend upward about 4 inches(10.2 centimeters) from floorboards 42, however side panels 46 may beconstructed to any suitable height. Side panels 46 and foot well areas40 prevent the feet and lower leg portions of the driver and passengerof ATV 10 from moving outside of cab 17 when ATV 10 is in motion, forexample when traversing rough terrain. In other embodiments (not shown),side panels 46 may be removed to allow easier entry and exit into cab 17of ATV 10.

Referring now to FIG. 7, an illustrative embodiment of a side-by-sideATV 48 is shown. ATV 48 includes driver's side seat 49, side panel 52,and engine cover 54. Tube 56 extends upward from engine cover 54 to formprotective cage 16. Seat guard 50 is coupled between engine cover 54 andside panel 52 to prevent a passenger positioned on seat 49 from slidinglaterally off of seat 49 during vigorous driving. Additionally, seatguard 50 may provide protection against passing external obstacles. Seatguard 50 may also be included on the passenger's side of ATV 48.

Referring now to FIG. 8, another illustrative embodiment of ATV 48 isshown including an additional safety bar 58. In this embodiment, safetybar 58 couples between tube 56 and seat guard 50 to further enclose apassenger in the cab area of ATV 48. Additionally, safety bar 58 may beused as a handle when entering or exiting ATV 48. Safety bar 58 may alsobe included on the passenger's side of ATV 48. Additionally, there maybe a panel or restrictive member, such as a mesh netting, placed betweenone or more of seat guard 50, safety bar 58, tube 56 and side panel 52to further restrict the driver's or passenger's appendages from exitingthe vehicle during vigorous driving.

Referring now to FIG. 9, an illustrative bottom plan view of ATV 10 isshown. For simplicity, the floorboards and bottom side shielding havebeen removed. In this embodiment, driver's side 65 of ATV 10 is shown onthe upper portion of FIG. 9 and passenger's side 63 is shown on thelower portion of FIG. 9. Longitudinal axis 66 separates driver's side 65from passenger's side 63 and defines the longitudinal center line of ATV10. In this embodiment, various relatively heavy components arepositioned vertically proximate the frame 15 to lower the vehicle'scenter of gravity, thereby improving balance and stability. For example,fuel tank 62 is positioned under lower seating surface 20 b onpassenger's side 63 of ATV 10. Fuel tank 62 is supported by frame 15. Asshown, fuel tank 62 is L-shaped, however any suitably shaped fuel tankmay be used. Positioning fuel tank 62 on passenger's side 63 improvesthe balance of ATV 10 when only a driver is present on driver's side 65of ATV 10. Battery 64 is positioned under lower seating surface 20 a ondriver's side 65 of ATV 10. In this embodiment, battery 64 is positionednear axis 66 and relatively low on the ATV 10, thereby improvingbalance. Positioning of battery 64 near the seating surface 20 a alsoallows for easier serviceability and for reduced routing of lines to theengine assembly 34.

Referring now to FIGS. 10-13, front end 12 of ATV 10 is shown in greaterdetail. Front end 12 includes hood 32, which may be removably coupled tofront panel 67. As illustrated, a hood mounting assembly includes a pairof plungers or pegs 95 which are removably received within cylindricalgrommets 97. Plungers 95 are fixed near the rear corners of the hood 32,while grommets 97 are fixed to the front panel 67 near the rear cornersof a storage area 68. In this embodiment, plungers 95 and grommets 97are illustratively formed of steel and a resilient material (such as anelastomer), respectively, however any suitable material may be used. Thefront of hood 32 includes a plurality of flanges 99 a which areconfigured to cooperate with a lip 99 b formed within front panel 67,thereby defining a releasable hinge.

In this illustrative embodiment, storage area 68 and access panel 61 arepositioned under hood 32. Storage area 68 may receive a tool kit, cargonet or any other suitable vehicle accessory for ATV 10. Access panel 61may include any suitable engine or vehicle maintenance port or terminal,such as a radiator fill cap, battery charging terminals, oil fill plug,or transmission fill plug.

Referring now to FIG. 14, one illustrative embodiment of frame 15 of aside-by-side ATV such as ATV 10 shown in FIG. 1 is shown. Frame 15includes inner rails 72, front crossmember 71, mid crossmember 73, andrear crossmember 77. Frame 15 also includes outer tubes 70 that definethe outermost width of frame 15. Rear assembly 92 is coupled to upperframe rails 90 and cross-member 77 and is described in more detailbelow. The portion of frame 15 between mid crossmember 73 and rearcrossmember 77 supports modular engine assembly 34 of ATV 10. In thisembodiment, modular engine assembly 34 may include a transmission 136such as a continuously variable transmission, and a rear differential132 prior to being installed in frame 15, as shown in FIG. 15.

Referring to FIGS. 14 and 15, inner rails 72 of frame 15 are coupledtogether on a front end by crossmember 71 and on the rear end by rearcrossmember 77. Brackets 76 couple upper frame tubes 88, upper framerails 90, vertical tubes 74, and outer tubes 70 together on each side ofATV 10. Outer tubes 70 are coupled to inner rails 72 by brackets 69.Vertical tubes 74 are coupled on a lower end to inner rails 72. Upperframe tubes 88 are coupled to support tubes 83 which are coupled on alower end to inner rails 72. Upper frame rails 90 are coupled on a rearend to cross tube 91.

As shown in FIG. 15, modular engine assembly 34 may be preassembledbefore being installed in frame 15. During the construction of frame 15,upper brace 78 is attached to frame 15 to provide dimensional stabilityduring welding. During installation of modular engine assembly 34, upperbrace 78 is removed from frame 15 and modular engine assembly 34 isplaced on frame 15. Upper brace 78 is then reattached to frame 15. Moreparticularly, after modular engine assembly 34 is positioned betweenupper frame rails 90 in frame 15, as shown in FIG. 14, upper brace 78may be installed.

Upper brace 78 includes outer brackets 86, rear bracket 84, crossmember80 and angular members 82. Angular members 82 are coupled together on anend by bracket 84 and on an opposing end by crossmember 80. Each bracket86 is substantially U-shaped and includes apertures 85. U-shapedbrackets 86 are adapted to overlap upper frame tubes 88. Apertures 85 inbrackets 86 and apertures 87 in upper frame tubes 88 align and acceptfasteners to secure upper brace 78 to upper frame tubes 88. Bracket 84includes apertures 81 which align with aperture 89 in cross tube 91 andmay be secured using any suitable fasteners.

In this embodiment, modular engine assembly 34 is mounted on frame 15 ofATV 10 using a three position mounting system to allow modular engineassembly 34 to be dropped into frame 15 and bolted or attached as oneunit. Illustrative embodiments of each of the three mounting assembliesare shown in FIGS. 16 through 18. Referring now to FIG. 16, mountingsystem 94 positioned on the driver's side of modular engine assembly 34and frame 15 is shown. Bracket 96 is mounted to modular engine assembly34 prior to installation of modular engine assembly 34 in frame 15.Lower bracket 102 is coupled to rail 75 of frame 15 and receivesmounting plate 100. Mounting plate 100 is coupled to bracket 102 byfasteners 104.

During installation of modular engine assembly 34 into frame 15, bracket96 is aligned with mounting plate 100 and fastener 98 is positioned inan aperture in bracket 96 and aperture 101 of mounting plate 100 tosecure bracket 96 and modular engine assembly 34 to frame 15. Similarly,mounting assembly 120, as shown in FIG. 18, is positioned on thepassenger's side of modular engine assembly 34 and frame 15. Bracket 128is coupled to frame 15. Mounting plate 126 is coupled to bracket 128 byfasteners 130. Bracket 122 is coupled to the passenger's side of modularengine assembly 34 and is positioned such that an aperture in bracket122 aligns with central aperture 127 of mounting plate 126 when modularengine assembly 34 is installed in frame 15. Fastener 124 extendsthrough the aperture in bracket 122 and aperture 127 in mounting plate126 to secure modular engine assembly 34 to frame 15.

Modular engine assembly 34 is also mounted to frame 15 by a thirdmounting assembly shown in FIGS. 14 and 17. Mounting assembly 106includes bracket 108, side plates 116, and mounting plate 114. Bracket108 couples to brackets 93 of rear assembly 92. Bracket 108 includesvertically extending plates 110 and is coupled to brackets 93 byextending fasteners (not shown) through apertures 109. Side plates 116are coupled to rear differential 132 of engine assembly 34. Mountingplate 114 is coupled between side plates 116 by fasteners 118. Duringinstallation of modular engine assembly 34 in frame 15, verticallyextending plates 110 of bracket 108 are positioned one each side ofmounting plate 114. Fastener 112 is then positioned through apertures invertically extending plates 110 and aperture 115 of mounting plate 114to secure modular engine assembly 34 in frame 15.

Referring now to FIG. 19, a partial forward-facing, bottom sideperspective view of the drivetrain components of ATV 10 is shown.Modular engine assembly 34 includes engine 133, transmission 136, andrear differential 132. In this embodiment, the crankshaft (not shown) ofengine 133 is parallel with the fore/aft direction of ATV 10 andprovides for a narrower overall vehicle width and improved center ofgravity of ATV 10. In this embodiment, engine 133 is a 760 cc engineproducing about 50 horsepower. Engine 133 produces excellentacceleration characteristics and responsiveness. ATV 10 weighs about 950pounds (430.9 kilograms) and has a power to weight ratio of about0.053/1 (horsepower/pound). Any suitable engine may be used in ATV 10,and ATV 10 may be constructed to any suitable weight, however thepresent invention contemplates ATVs having a power to weight ratio of atleast 0.045/1 (horsepower/pound).

Rear differential 132 of modular engine assembly 34 is directly coupledto transmission 136 by housing 148 to maintain center distances andallow for easy assembly. In this illustrative embodiment, reardifferential 132 is an electric rear lockable differential, however anysuitable rear differential or rear axle may be used. Output shaft 138extends outward from transmission 136 toward the front of ATV 10 androtates to power front wheels 24 a of ATV 10. In this embodiment, ATVhas on-demand all-wheel drive with switchable backdrive, however anysuitable drivetrain such a two-wheel drive or four-wheel drive may beused.

As shown in FIG. 19, output shaft 138 extends under protective panel134. Protective panel 134 is positioned behind upper and lower seatingsurfaces 18 a, 18 b and 20 a, 20 b and protects passengers in ATV 10from moving parts of modular engine assembly 34, as well as, assists inshielding from noise. The extending end of output shaft 138 includessplined portion 140 which is adapted to engage the interiorcircumference of coupler 142. Coupler 142 is coupled to universal joint144. Universal joint 144 connects coupler 142 to front drive shaft 146which powers the front wheels of ATV 10. Coupler 142 may move in a foreand aft direction on splined portion 140 of output shaft 138 whileremaining engaged with splined portion 140. During vigorous driving,front drive shaft 146 may move in the fore and aft direction causingcoupler 142 to slide longitudinally on splined portion 140 of outputshaft 138 while front drive shaft 146 remains rotationally coupled withoutput shaft 138.

Referring now to FIGS. 20 and 21, components of the rear suspension ofATV 10 is shown. Rear frame assembly 92 is formed by down tubes 105,vertical tubes 107, rear brackets 160, front brackets 162, lower tubes180, and cross tubes 182 and 184. Down tubes 105 are coupled to upperframe rails 90 and extend rearward. Lower tubes 180 are coupled to rearcrossmember 77 on one end. The opposing ends of lower tubes 180 arecoupled together by cross tube 182. Cross tube 182 supports hitch 164which may be used to couple to a trailer or other device for towingbehind ATV 10. The lower ends of down tubes 105 are coupled together bycross tube 184. Front brackets 162 and rear brackets 160 extend betweenlower tubes 180 and down tubes 105. Vertical tubes 107 extend downwardfrom upper frame rails 90 and couple to down tubes 105. Each down tube105 includes bracket 186. Similarly, each vertical tube 107 includesbracket 176.

Rear wheels 24 b include inner hub assemblies 25. The lower ends ofupper and lower control arms 172 and 170 are coupled to inner hubassemblies 25 of rear wheels 24 b. The lower ends of dampeners 168 arealso coupled to inner hub assemblies 25. The upper ends of upper andlower control arms 172 and 170 are pivotally coupled to front and rearbrackets 162 and 160 on each side of ATV 10. Upper ends 178 of dampeners168 are coupled to brackets 176 on vertical tubes 107. Stabilizer ortorsion bar 174 is coupled to inner hub assemblies 25 by rods 171. Moreparticularly, rods 171 have upper ends connected to opposing ends oftorsion bar 174 and lower ends connected to lower control arms 170.Torsion bar 174 is coupled to brackets 186 on down tubes 105 andprovides a torsional transverse connection between the lower controlarms 170 of rear wheels 24 b.

Rear wheels 24 b may move vertically in an independent manner along apath defined by upper and lower control arms 172 and 170. For example,when ATV 10 encounters rough terrain, rear wheels 24 b may move upwardand downward to maintain contact with a ground surface. By positioningbrackets 176, which couple to dampeners 168, on vertical tubes 107 offrame 15, the load path generated when rear wheels 24 b move upward istranslated through vertically orientated frame members (vertical tubes107) of frame 15. Additionally, torsion bar 174 provides interactionbetween the independent suspensions of the rear wheels 24 b throughrespective control arms 170. As known in the art, during a turn, torsionbar 174 resists deflection of an outer rear wheel 24 b due tocentrifugal force by transmitting deflection to the inner rear wheel 24b. These elements may improve the ride and handling characteristics ofATV 10.

Referring now to FIGS. 22-24, components of the front suspension,including right front brake assembly 199 are shown. Front frame assembly203 includes front tubes 204 coupled to an upper crossmember 205. Reartubes 207 are positioned rearwardly of the front tubes 204 and arecoupled to angled braces 209 and crossmember 71 (FIG. 14). Upperbrackets 211 are supported by front tubes 204 and braces 209, whilelower brackets 213 are supported by lower tubes 215. The lower ends ofupper and lower control arms 210 and 212 couple to inner hubs 25 ofwheels 24 a. Lower ends of steering arms 208 (commonly called tie rods),and dampeners 217 are also coupled to inner hubs of wheels 24 a. Theupper ends of upper and lower control arms 210 and 212 are pivotallycoupled to lower brackets on each side of ATV 10. Upper ends ofdampeners 217 are pivotally coupled to bracket 223 extending betweenrear tubes 207. The control arms 210, 212 and dampeners 217 cooperate todefine independent front suspensions for the right and left front wheels24 a. More particularly, front wheels 24 a may move vertically in anindependent manner along a path defined by upper and lower control arms210 and 212.

With further reference to FIGS. 22 and 23, a stabilizer or torsion bar214 is coupled to front tubes. Links or rods 219 a and 219 b areoperably coupled to opposing left and right ends of torsion bar 214,illustratively through left and right clamps 225 a and 225 b and torquebars 221 a and 221 b, respectively. Rods 219 are coupled to inner hubassemblies 25 of right and left front wheels 24 a through upper controlarms 210. In use, when a force is exerted on one of the right and leftfront wheels 24 a during vehicle travel, the front suspension maytransmit a corresponding force on the other of the left and right frontwheel 24 a. For example, when an upward force is exerted on the leftfront wheel 24 a due to, e.g., a bump or a turn, the corresponding upperand lower control arms 210 and 212 may move upward relative to the ATV10. Such upward movement may urge the corresponding rod 219 a upward,which may cause the corresponding end of the left torque bar 221 a tomove upward. The left torque bar 221 a may act as a lever, exerting atorque on the left end of the torsion bar 214.

The torsion bar 214 may include a torque transfer regulator (not shown),which determines how much of the torque exerted by the left torque bar221 a (or right torque bar 221 b) is transferred to the right torque bar221 b (or left torque bar 221 a). Clamps 225 a and 225 b may berepositioned or moved along torque bars 221 a and 221 b to change thesuspension effect. In the current example, upward movement of the lefttorque bar 221 a may cause upward movement of the right torque bar 221b, thereby urging the right rod 219 b and connected control arms 210 and212 upward. The upward movement of the right control arms 210 and 212may exert an upward force on the right front wheel 24 a. Thus, the frontsuspension may exert on the right front wheel 24 a a portion of theupward force that a travel surface exerts on the left front wheel 24 a.While the current example involved a force exerted by the travel surfaceon the left front wheel 24 a, the front suspension may operate in asimilar manner when a force is exerted by the travel surface on theright front wheel 24 a. An illustrative embodiment torsion bar isdisclosed in U.S. patent application Ser. No. 11/340,301, filed Jan. 26,2006, which is expressly incorporated by reference herein.

For simplicity, only right front brake assembly 199 is shown in FIGS. 22and 23, however a similar brake assembly may be used for each wheel 24of ATV 10. Front brake assembly 199 is coupled to inner hub 25 of wheel24. Front axle 206 is supported by inner hub assembly 25. As detailedabove, upper control arms 210, lower control arms 212, and steering arms208 couple to inner hubs 25 of wheels 24 a. Steering arm 208 ispositioned above and rearward of front axle 206 to allow caliper bracket201 and caliper 200 to be positioned rearward or on the back side offront axle 206. Control arm 210 is positioned above steering arm 208 tofacilitate the relative positioning of steering arm 208 and hence,caliper bracket 201 and caliper 200. Caliper bracket 201 and brake disc202 are also coupled to inner hub 25 of wheel 24. Brake caliper 200 iscoupled to the back or rearward facing end of caliper bracket 201. Theplacement of brake caliper 200 on the rearward facing end of caliperbracket 201 prevents mud and debris from piling up on top of caliper 200as tire 22 rotates forward or counterclockwise. Placement of caliper 201on the frontward facing side or end of brake disc 202 may require awiper or housing to prevent mud and debris from tire 22 from piling upon caliper 200.

Referring now to FIGS. 25 and 26, an elevated perspective view and arear profile view of engine cover 19 of ATV 10 is shown. Modular engineassembly 34 includes engine cooling intake 220 and clutch cooling intake218. Intakes 218 and 220 extend upward through opening 216 in enginecover 19 and direct cooling air to clutch housing 135 and engine 133.Clutch housing 135 protects a clutch mechanism adapted to transmit powerfrom engine 133 to transmission 136. Intakes 218 and 220 are positionedbetween driver and passenger upper seating surfaces 18 to collect airpassing between upper seating surfaces 18 a and 18 b when ATV is drivenin the forward direction. As ATV 10 increases in speed, more air passesbetween upper seating surfaces 18 a and 18 b and is collected by intakes218 and 220.

Referring now to FIG. 27, a partial perspective view of the driver'sside of cab 17 of ATV 10 is shown. As described above, cab 17 includesupper seating surface 18, lower seating surface 20, steering wheel 28and front console 31. In this illustrative embodiment, accelerator 226and brake pedal 224 are positioned in footwell 40 of cab 17.

Referring now to FIG. 28, an exploded view of a steering assembly thatmay be used on an ATV such as ATV 10 is shown. In this illustrativeembodiment, steering wheel 28 may be tilted by pivoting about a pivotaxis 227, as shown in FIG. 29. Illustratively, steering wheel 28 may beinfinitely adjusted, i.e. in a continuous manner, throughout apredefined angular range of motion a. In the illustrated embodiment, ais defined to be approximately 42 degrees. In a further illustrativeembodiment, steering wheel 28 may be adjusted telescopically in adirection along a longitudinal axis 228.

Steering wheel 28 is coupled to rod 234 which extends through tiltbracket 30. Rod 234 is connected to coupler 242 which translatesrotation of steering wheel 28 and rod 234 to universal joint 244.Universal joint 244 is coupled to an upper end of steering shaft 246.The lower end of steering shaft 246 is coupled to universal joint 248which translates the rotation of steering shaft 246 to a front gearboxassembly 247 and steering arms 208 (FIG. 22) to turn front wheels 24.Tilt bracket 30 is pivotally coupled to bracket 250 by a fastenerassembly 235, defining pivot axis 227. Fastener assembly 235 may includeconventional bolts 235 a, washers 235 b, and nuts 235 c. Bracket 250includes lower arm 232. Lower end or mount 240 of adjustment device 230is coupled to arm 232 of bracket 250. Upper end or mount 238 ofadjustment device 230 is coupled to tabs 236 of tilt bracket 30. Whensteering wheel 28 is tilted upward, adjustment device 230 is extendedand tilt bracket 30 is rotated upward. Conversely, when steering wheel28 is tilted downward, adjustment device 230 is retracted and tiltbracket 30 is rotated downward.

In the illustrated embodiment, adjustment device 230 comprises a gasspring having a cylinder 252 and a movable piston rod 254. A lever 256is operably coupled to the piston rod 254 and is configured toselectively block fluid flow within the cylinder 252. In operation, thelever 256 is in a rest position when it blocks fluid flow and locks therod 254, and hence steering wheel 28, in position. Activation of thelever 256 permits fluid flow within the cylinder 252 and thus adjustmentof the rod 254, and steering wheel 28. In one illustrative embodiment,adjustment device 230 comprises a Bloc-O-Lift® gas spring available fromStabilus.

Referring now to FIG. 30, an adjustable grab bar for a passenger ridingin ATV 10 is shown. Adjustable grab bar 190, also shown in FIGS. 22 and23, is positioned in front dash panel 195 of ATV 10 and extends rearwardtoward a passenger seated in cab 17. Adjustable grab bar 190 includeshandle portion 192, tubes 193 and 194, and locking mechanism 196. Thepassenger may telescopically adjust the position of handle portion 192.Tube 193 may be extended out of and retracted within tube 194 to allowthe passenger to adjust the position of handle portion 192 duringingress or egress from cab 17 of ATV 10. Locking mechanism 196 securestube 193 and handle portion 192 in the desired position.

While this invention has been described as having an exemplary design,the present invention may be further modified within the spirit andscope of this disclosure. This application is therefore intended tocover any variations, uses, or adaptations of the invention using itsgeneral principles. Further, this application is intended to cover suchdepartures from the present disclosure as come within known or customarypractice in the art to which this invention pertains.

What is claimed is:
 1. An all-terrain vehicle, comprising: a frame; afront suspension comprising at least one right front control arm and oneleft front control arm, the front control arms being coupled to theframe, and a front torsion bar coupled between the front control arms;at least two front wheels coupled to the front suspension; a rearsuspension comprising at least one right rear control arm and one leftrear control arm, the rear control arms being coupled to the frame, anda rear torsion bar coupled between the rear control arms; at least tworear wheels coupled to the rear suspension; a seating area supported bythe frame and comprising side by side seats each having a seat back anda seat bottom; a fuel tank being positioned underneath one of the seatbottoms; a rear axle assembly drivingly coupling the transmission to therear wheels; a modular engine assembly supported by the frame, themodular engine assembly being comprised of an engine, a transmissioncomprising a continuously variable transmission and at least a portionof the rear axle assembly, the portion of the rear axle assembly havinga rear drive axis, wherein the modular engine assembly is capable ofbeing mounted to or dismounted from the frame as a unit; thecontinuously variable transmission comprising: a clutch mechanismadapted to transmit power from the engine to the transmission; a clutchhousing covering the clutch mechanism, and a clutch cooling intake whichcommunicates with the clutch housing to cool the clutch mechanism; themodular engine assembly being positioned rearward of the seating areaand being mounted to the frame by first and second mounting assemblies,where the first mounting assembly is coupled to the rear axle assemblyrearward of the rear drive axis and wherein the second mounting assemblyis coupled to the engine; a front axle assembly supported by the frameand drivingly coupling the transmission to the front wheels; a front endcomprising an outer front panel having outer fenders and a hood; a cabincluding a steering wheel and a transmission shift lever, the seatingarea being positioned within the cab; a rear end including an enginecover; a protective cage positioned over the cab including front andrear frame tubes extending upwardly from the cab to form the protectivecage; and wherein outermost points of the vehicle in a width-wisedirection define a width of less than 54 inches.
 2. The vehicle of claim1, wherein the first mounting assembly includes at least one firstbracket coupled to the portion of the rear axle assembly, and a firstmounting plate positioned between the first bracket and frame; and thesecond mounting assembly includes at least one second bracket coupled tothe engine, and a second mounting plate positioned between the secondbracket and frame.
 3. The vehicle of claim 1, further comprising a thirdmounting assembly coupling the modular engine assembly to the frame. 4.The vehicle of claim 1, wherein the vehicle width is approximately 50inches and wherein the vehicle further comprises a battery positionedunderneath one of the seat bottoms.
 5. The vehicle of claim 1, an inletto the clutch cooling intake is at a position higher than thetransmission.
 6. The vehicle of claim 1, wherein the vehicle width isapproximately 50 inches.
 7. The vehicle of claim 1, further comprising afront drive shaft coupling the transmission to the front wheels.
 8. Thevehicle of claim 7, wherein the front drive shaft extends laterallyintermediate the side by side seats.
 9. The vehicle of claim 7, furtherincluding a battery positioned vertically below one of the passengerseating surface and driver seating surface.
 10. The vehicle of claim 9,wherein the front driveshaft extends laterally between the fuel tank andthe battery.
 11. The vehicle of claim 1, further defining a weight and apower to weight ratio, the power to weight ratio being equal to at least0.045/1 horsepower/pound.
 12. The vehicle of claim 1, wherein thevehicle width is defined by the outer sides of the front wheels.
 13. Thevehicle of claim 1, wherein the engine cover is supported by an upperrear frame portion and extends over one of the engine and transmissionrearward of the seating area.
 14. The vehicle of claim 13, wherein theengine cover comprises a floor and upstanding sidewalls.
 15. The vehicleof claim 13, wherein the upper rear frame portion comprises a rear bracepositioned over the engine and transmission.
 16. The vehicle of claim15, wherein the rear brace is removable to define an upper opening forinstallation of the modular engine assembly.
 17. The vehicle of claim 1,wherein each seat bottom has a seating surface with a low point of theseating surface being lower than a top of the engine, the side by sideseating surfaces including a driver seating surface and a passengerseating surface.
 18. The vehicle of claim 1, further comprising fronttires mounted to the front wheels.
 19. The vehicle of claim 18, whereinouter surfaces of the front tires define the outermost points.
 20. Thevehicle of claim 1, wherein outer surfaces of the outer fenders definethe outermost points.
 21. The vehicle of claim 1, further comprising afront console and an adjustable steering wheel.
 22. The vehicle of claim21, further comprising an adjustment device configured to lock theadjustable steering wheel in a selected position, the adjustment devicebeing continuously adjustable within a range of motion.
 23. The vehicleof claim 1, further comprising a transmission shift lever intermediatethe seat bottoms.
 24. The vehicle of claim 1, further comprising avehicle cover, including one or more of a roof, a windshield and doors.25. The vehicle of claim 1, wherein the cab defines an operator andpassenger entry.
 26. The vehicle of claim 1, wherein the cab has sidepanels located along a front margin of the operator and passenger entry,a lower edge of the operator and passenger entry, and a rear edge of theoperator and passenger entry.
 27. The vehicle of claim 1, furthercomprising a front storage enclosure positioned under the hood, theenclosure having walls that restrain movement of items placed therein.28. The vehicle of claim 1, further comprising a protective panelpositioned between the side by side seats and the engine.
 29. Theall-terrain vehicle of claim 28, wherein a front driveshaft couples thetransmission to the front wheels, and the front driveshaft extends underthe protective panel.
 30. The vehicle of claim 1, wherein a rear-mostpoint of the rear axle assembly is behind a rear-most point of thetransmission.